Electrical generator with an electrical bus connectable to different electrical power sources and different loads

ABSTRACT

An electrical generator that is configured to simultaneously output different types of electrical power so that electrically powered components that require different types of electrical power can be simultaneously powered by the electrical generator. The electrical generator can be used at any location where electrically powered components that require different types of electrical power are utilized. Instead of or in addition to outputting different types of electrical power, the electrical generator can also be configured to output at least one type of electrical power as well as a cooling liquid for use in cooling an external heat generating component.

FIELD

This technical disclosure relates to an electrical generator that cansimultaneously output different types of electrical power, as well asoutput a thermal control fluid for use in thermal control of a componentthat may or may not be electrically connected to one of the electricalpower outputs of the electrical generator.

BACKGROUND

The use of electrical generators to provide electrical power tocomponents is known. One example use of an electrical generator is on ajob site where line power (also known as utility power) may not bepresent or where the electrical generator is used in place of linepower/utility power. In some instances, different components at a jobsite may require different types of electrical power, in which caseseparate electrical generators may be used to power the differentcomponents.

SUMMARY

An electrical generator and associated methods are described hereinwhere the electrical generator is configured to simultaneously outputdifferent types of electrical power so that electrically poweredcomponents that require different types of electrical power can besimultaneously powered by the electrical generator. The electricalgenerator can be used at any location where electrically poweredcomponents that require different types of electrical power areutilized. Instead of or in addition to outputting different types ofelectrical power, the electrical generator can also be configured tooutput at least one type of electrical power as well as a thermalcontrol fluid that can include, but is not limited to, a liquid, gas, ormixture thereof for use in thermal control (heating and/or cooling) ofan external component.

In one embodiment, the electrical generator is configured to generateand output a modulated electrical power that is output at a modulatedelectrical power output (which may also be referred to as a variablefrequency and/or variable amplitude power output), as well as configuredto generate and output an export (or standard) electrical power that isoutput at an export electrical power output (which may also be referredto as a synchronous electrical power output). An electrically poweredcomponent that requires modulated electrical power can be powered fromthe modulated electrical power output. An electrically powered componentthat requires export/standard/synchronous electrical power may also besimultaneously powered from the export electrical power output.

In one embodiment, the electrical generator can also be provided with athermal control system and can output a thermal control fluid, which canbe a liquid, gas, or mixture thereof, for thermal control of a componentat the job site. For example, the thermal control fluid can be a coolingfluid used to cool one of the electrically powered components receivingelectrical power from the electrical generator. In another embodiment,the thermal control fluid can be used to cool or heat an electricalcomponent that is not electrically powered by the electrical generator.After exchanging heat with the component, the thermal control fluid canbe pumped back to the electrical generator for heat exchange beforebeing returned back to the component for additional thermal control. Inone embodiment, the heat exchange of the thermal control fluid can occurentirely within the electrical generator via a heat exchanger that isinternal to the electrical generator. In another embodiment, the thermalcontrol fluid can be directed into a heat exchanger that is external tothe electrical generator but fluidly connected to the electricalgenerator to receive the thermal control fluid for heat exchange beforethe thermal control fluid is directed back into the electricalgenerator. In still another embodiment, the thermal control fluid can bedirected through both an internal heat exchanger and an external heatexchanger.

In another embodiment, a plurality of user interface modules can beprovided where each user interface module can be individually removablyinstalled on the electrical generator to control operation of theelectrical generator. In one embodiment, each user interface module canbe associated with a particular electrically powered component to bepowered by the modulated electrical power to appropriately control themodulated electrical power at the modulated electrical power outputbased on the particular electrically powered component connected to themodulated electrical power output. In another embodiment, each userinterface module can be associated with a particular electricallypowered component to be powered by the export electrical power toappropriately control the export electrical power at the exportelectrical power output based on the particular electrically poweredcomponent connected to the export electrical power output. The userinterface modules can be changed out based on the electrically poweredcomponent connected to (or to be connected to) the modulated electricalpower output and/or to the export electrical power output.

In one embodiment described herein, an electrical generator can includean engine having a mechanical output, a first electrical power outputthat outputs a first type of electrical power, and a second electricalpower output that outputs a second type of electrical power, where thesecond type of electrical power differs from the first type ofelectrical power. Conversion components are connected to the mechanicaloutput and to the first and second electrical power outputs, where theconversion components are configured to convert the mechanical outputinto the first type of electrical power and the second type ofelectrical power. The first type of electrical power output at the firstelectrical power output can be direct current electrical power, and thesecond type of electrical power output at the second electrical poweroutput can be synchronous alternating current electrical power.Alternatively, the first type of electrical power output at the firstelectrical power output can be modulated alternating current electricalpower, and the second type of electrical power output at the secondelectrical power output can be synchronous alternating currentelectrical power. In another embodiment, the first type of electricalpower output at the first electrical power output can be direct currentelectrical power, and the second type of electrical power output at thesecond electrical power output can be modulated alternating currentelectrical power. In another embodiment, the electrical generator canhave more than two electrical power outputs with any combination ofmodulated alternating current electrical power, synchronous alternatingcurrent electrical power, and direct current electrical power.

In another embodiment described herein, an electrical generator caninclude an engine having a mechanical output, conversion componentsconnected to the mechanical output that are configured to convert themechanical output into at least one alternating current that is outputfrom at least one alternating current output, and a thermal controlsystem that can output a thermal control fluid, which can be a liquid,gas or mixture thereof, from the electrical generator for cooling orheating an external component. The thermal control system can include atank configured to contain a thermal control fluid, a pump connected tothe tank, a heat exchanger connected to the pump, and a first flow pathbetween the thermal control system and a thermal control fluid outletconnector that can be connected to in order to direct thermal controlfluid to a component external to the electrical generator. In thisembodiment, the electrical generator not only provides electrical power(for example modulated electrical power and/or export electrical power)but also provides a thermal control fluid for thermal control of acomponent that is external to the electrical generator.

In another embodiment described herein, a system can include anelectrical generator as described herein, a first component of ahorizontal directional drilling system connected to the first electricalpower output of the electrical generator, and a second component of ahorizontal directional drilling system connected to the secondelectrical power output of the electrical generator.

In another embodiment described herein, a system can include anelectrical generator as described herein, and a plurality of userinterface modules. Each user interface module is individually removablyinstallable on the electrical generator to control operation of theelectrical generator, and each user interface module is configured tocontrol the electrical power that is output at the electrical poweroutput whereby the electrical power differs for each user interfacemodule.

In another embodiment described herein, a method can include connectingan electric drive motor of an implement/device including, but notlimited to, a pit pump, to an electrical power output of an electricalgenerator controlled by a first user interface module. Thereafter, thefirst user interface module is removed and a second user interfacemodule is installed that is configured to operate with a secondelectrically operated implement other than the electric drive motor ofthe first implement. The electric drive motor of the first implement isdisconnected from the electrical power output of the electricalgenerator, and the second electrically operated implement is connectedto the electrical power output of the electrical generator.

DRAWINGS

FIG. 1 is a schematic illustration of the electrical generator describedherein powering different electrically powered components.

FIG. 2 is a schematic illustration of one embodiment of an electricalsystem architecture of the electrical generator described herein.

FIG. 3 is a schematic illustration of another embodiment of anelectrical system architecture of the electrical generator describedherein.

FIG. 4 is a schematic illustration of still another embodiment of anelectrical system architecture of the electrical generator describedherein.

FIG. 5 is a schematic illustration of one embodiment of a thermalcontrol system architecture of the electrical generator describedherein.

FIG. 6 is a schematic illustration of another embodiment of a thermalcontrol system architecture of the electrical generator describedherein.

FIG. 7 is a schematic illustration of still another embodiment of athermal control system architecture of the electrical generatordescribed herein.

FIG. 8 is a schematic illustration of an embodiment of a control systemarchitecture of the electrical generator described herein.

FIG. 9 is a schematic illustration of the electrical generator describedherein used at a site where horizontal directional drilling isoccurring.

FIG. 10 is a schematic illustration of a plurality of the electricalgenerators described herein connected in parallel for powering a load.

FIG. 11 is a perspective view of another embodiment of an electricalgenerator described herein where the electrical outputs are incorporatedinto output modules.

FIG. 12 is a front view of the electrical generator of FIG. 11 with themodules installed.

FIG. 13 is a cross-sectional side view of the electrical generator ofFIG. 11 .

FIG. 14 illustrates a plurality of the electrical generators of FIG. 11paralleled together.

FIG. 15 schematically depicts a common bus connection of the paralleledelectrical generators.

FIG. 16 is a schematic illustration of another embodiment of anelectrical system architecture of an electrical generator describedherein.

FIG. 17 schematically depicts another example of a common busconnection.

FIG. 18 schematically depicts another example of a common busconnection.

FIG. 19 schematically depicts an example of integrated common bus andthermal control fluid manifolds.

FIG. 20 schematically depicts one example of integrating the common busand thermal control fluid manifolds.

DETAILED DESCRIPTION

Referring to FIG. 1 , an electrical generator 10 as described in moredetail below is illustrated. The electrical generator 10 is configuredto simultaneously output different types of electrical power from atleast two different electrical outputs 12, 14. The electrical output 12may be considered a first electrical output or a second electricaloutput, while the electrical output 14 may be considered a secondelectrical output (if the electrical output 12 is considered the first)or a first electrical output (if the electrical output 12 is consideredthe second). Different electrically powered components 16, 18 thatrequire different types of electrical power can receive power from theoutputs 12, 14 so as to be simultaneously powered by the electricalgenerator 10. In some embodiments, both of the components 16, 18 neednot be powered simultaneously. Instead, the electrical generator 10 canbe used to power only the component 16 or only the component 18. Thedifferent types of electrical power that can be output from the outputs12, 14 can include direct current electrical power and an alternatingcurrent electrical power, or different forms of alternating currentelectrical power such as modulated alternating current electrical power(which may also be referred to as a variable frequency and/or variableamplitude power output) and synchronous alternating current electricalpower.

In one embodiment, the output 12 can be a direct current output thatoutputs a direct current (DC) electrical power that is then converted bya power converter externally of the electrical generator 10 into eithera modulated, alternating current (AC) electrical power or a synchronousAC electrical power depending upon the electrical power requirements ofthe component 16. In another embodiment, the output 12 can output amodulated AC electrical power or a synchronous AC electrical powerrequired by the component 16 where the power converter and theconversion into the modulated or synchronous AC electrical power occursinternally of the electrical generator 10. In another embodiment, theoutput 12 can output DC electrical power that is not converted to AC. Insome embodiments, the output 12 may be referred to as a modulatedelectrical power output that outputs modulated electrical power (whichmay also be referred to as a variable frequency and/or variableamplitude power output).

Similarly, the output 14 can be a direct current output that outputs DCelectrical power that is then converted by a power converter externallyof the electrical generator 10 into either a modulated, alternatingcurrent (AC) electrical power or a synchronous AC electrical powerdepending upon the electrical power requirements of the component 18. Inanother embodiment, the output 14 can output a modulated AC electricalpower or a synchronous AC electrical power required by the component 18where the power converter and the conversion into the modulated orsynchronous AC electrical power occurs internally of the electricalgenerator 10. In another embodiment, the output 14 can output DCelectrical power that is not converted to AC. In some embodiments, theoutput 14 may be referred to as an export electrical power output thatoutputs an export (or standard or synchronous) AC electrical powerrequired by the component 18.

In some embodiments, the component 16 may be powered by the output 14and the component 18 may be powered by the output 12.

The component 16 may be electrically connected to the output 12 via apower line 20, while the component 18 may be electrically connected tothe output 14 via a power line 22. In addition, a data line 24 can beprovided between the component 16 and the electrical generator 10 totransmit various data between the electrical generator 10 and thecomponent 16, while a data line 26 can be provided between the component18 and the electrical generator 10 to transmit various data between theelectrical generator 10 and the component 18. In addition, as discussedin further detail below, in some embodiments thermal control fluidsupply and return lines 28 a, 28 b (depicted in dashed lines) can extendbetween the electrical generator 10 and the component 16 and/or thermalcontrol fluid supply and return lines 30 a, 30 b (depicted in dashedlines) can extend between the electrical generator 10 and the component18.

In addition, one or more additional ones of the components 16 may beconnected to one another in series as illustrated (or in parallel) withone or more power, data and/or thermal control fluid lines 17 connectingthe components 16. Similarly, one or more additional ones of thecomponents 18 may be connected to one another in series as illustrated(or in parallel) with one or more power, data and/or thermal controlfluid lines 19 connecting the components 18.

The electrical generator 10 illustrated in FIG. 1 is useful in locationswhere different electrically powered components, such as the components16, 18, are used that have different electrical power requirements. Forexample, the component 16 may be an electrically powered component orsystem that experiences variable loads. Examples of the components 16that can be powered by the electrical generator 10 include, but are notlimited to, an electric drive motor of a pit pump used at a horizontaldirectional drilling site, one or more electrically powered componentsof a horizontal directional drilling (HDD) rig, a drilling mud cleaningsystem used with the HDD rig, a tool truck, maintenance trailer, a lightplant, a control cab, a building, a portable saw mill, a cement mixingplant, a welder, or a pipe flange facing machine.

The component 18 may be an electrically powered component that requiresstandard (or clean or synchronous) electrical power which may bereferred to as export power. Examples of the components 18 that can bepowered by the electrical generator 10 include, but are not limited to,the same components as the components 16 but configured to be run bysynchronous power; a heater at an HDD site; an air compressor; and handtools.

FIG. 2 illustrates one embodiment of an electrical system architectureof the electrical generator 10 that produces different electrical powersat the outputs 12, 14. In this embodiment, the output 12 outputs DCelectrical power that is then converted externally of the electricalgenerator 10 into modulated AC electrical power, while the output 14outputs synchronous AC electrical power. The electrical generator 10includes a housing 56 (illustrated in dashed lines) that houses some ofthe elements described herein. In this example, the electrical generator10 includes an engine 40, such as a diesel engine, a gasoline poweredengine, a propane powered engine, or the like, that outputs mechanicalenergy via an output shaft 42. The engine 40 can be powered by anysuitable engine fuel (wet/dry). Examples of suitable engine fuels thatcan be used include, but are not limited to, gasoline, diesel fuel,natural gas, propane, and the like.

In addition, conversion components are provided that convert themechanical energy of the output shaft 42 into the different electricalpowers at the outputs 12, 14. The conversion components can be anyelements suitable for generating the different electrical powers at theoutputs 12, 14. In the illustrated example, the conversion componentsinclude an electrical generating element 44, a first power converter 48,and a second power converter 50.

The electrical generating element 44 can be any device that is suitablefor converting the torque of the output shaft 42 into an AC output 46,for example single phase or 3-phase AC. In one non-limiting example, theelectrical generating element 44 can be a permanent magnet motor that ismechanically connected to and driven by the output shaft 42. Thepermanent magnet motor can be any permanent magnet motor that issuitable for converting the mechanical input of the shaft 42 into the ACoutput 46.

The power converter 48 is configured to receive the AC output 46 andconvert the AC to DC electrical power that is output along a DC outputbus 52. The power converter 48 can have any configuration that issuitable for converting the AC to DC.

In the illustrated example, the DC output bus 52 has at least twobranches, with one branch directing DC electrical power to the powerconverter 50. The power converter 50 converts the DC electrical powerinto the export, synchronous AC electrical power that is output at theelectrical power output 14. In one embodiment, the power converter 50can be configured to generate 120/240 VAC single phase AC that is outputfrom the output 14. In another embodiment, the power converter 50 cangenerate 480 VAC 3-phase AC that can be output from the output 14. Thepower converter 50 can have any configuration that is suitable forconverting DC electrical power into the synchronous AC electrical power.An example of the power converter 50 can be a DC to AC inverter.

The other branch of the DC output bus 52 directs the DC electrical powerto the output 12. In this embodiment, the electrical component 16 thatis electrically connected to the output 12 includes a power converter 54that is configured to convert the DC electrical power to modulated ACelectrical power for use by the electrical component 16. The powerconverter 54 can have any configuration that is suitable for convertingDC electrical power to modulated AC electrical power.

FIG. 3 illustrates another embodiment of an electrical systemarchitecture of the electrical generator 10 that can produce differentelectrical powers at electrical outputs thereof. Elements that areidentical to elements in FIG. 2 are referenced using the same referencenumerals. Like the embodiment in FIG. 2 , the embodiment in FIG. 3 canoutput DC electrical power at the output 12 that is then convertedexternally of the electrical generator 10 by the power converter 54 intomodulated AC electrical power, while the output 14 outputs synchronousAC electrical power. Instead of or in addition to the output 12, theembodiment in FIG. 3 can include an internal power converter 54' thatcan be similar in function and construction to the power converter 54and that converts the DC electrical power to modulated AC electricalpower internally within the electrical generator 10 and then directs themodulated AC electrical power to an output 12' for use by an externalelectrical component. Further, instead of or in addition to the output12 and the output 12', the embodiment in FIG. 3 can include an output 13that outputs DC electrical power for use by an external electricalcomponent requiring DC electrical power. Similarly, instead of or inaddition to the output 14, the embodiment in FIG. 3 can include anoutput 14' that outputs DC electrical power that is then convertedexternally of the electrical generator 10 by an external power converter50' into synchronous AC electrical power for use by the externalelectrical component 18 requiring synchronous AC electrical power.

The embodiment of the electrical generator 10 in FIG. 3 can include anytwo or more of the outputs 12, 12', 13, 14, 14' in any combinationthereof. In one embodiment, the electrical generator 10 in FIG. 3includes the output 12' and the output 14.

FIG. 4 illustrates another embodiment of an electrical systemarchitecture of the electrical generator 10 that can produce differentelectrical powers at different electrical outputs thereof. Elements thatare identical to elements in FIGS. 2 and/or 3 are referenced using thesame reference numerals, or the same reference numerals with the ending“-1” or “-2”. Like the embodiments in FIGS. 2 and 3 , the embodiment inFIG. 4 can output DC electrical power at the output 12 that is thenconverted externally of the electrical generator 10 by the powerconverter 54 into modulated AC electrical power. Alternatively, similarto the construction depicted in FIG. 3 , the electrical generator 10 inFIG. 4 can include an internal power converter 54'. In addition, theelectrical generator 10 in FIG. 4 can include two outputs 14-1, 14-2each of which outputs DC electrical power from the bus 52. Each of theDC electrical powers is then converted by an external power converter50-1, 50-2, respectively, into synchronous AC electrical power. Thepower converter 50-1 is configured for high power conversion, while thepower converter 50-2 is configured for lower power conversion. Highpower conversion can include, but is not limited to, generating power ofabout 50 kW or more. Lower power conversion can include, but is notlimited to, generating power of about 1.8 kW (or about 15 amps), orabout 3.6 kW (or about 30 amps). The power from the power converter 50-1can be used to power a device requiring synchronous AC electrical powerincluding, but not limited to, a device with higher power requirements,for example up to about 50 kW or more. The power from the powerconverter 50-2 can be used to power a device requiring synchronous ACelectrical power including, but not limited to, a device with lowerpower requirements, for example about 1.8 kW (or 15 amps) or about 3.6kW (or about 30 amps).

In another embodiment, the electrical generator 10 can be connected toone or more alternative power sources that are external to theelectrical generator 10. The electrical generator 10 may receiveelectrical power from these alternative power sources and/or theelectrical generator 10 may direct electrical power to these alternativepower sources. In this embodiment, the electrical generator 10 may alsobe referred to as an energy handling system since the electricalgenerator 10 can handle electrical energy from and/or direct electricalpower to multiple electrical power sources, including an internalelectrical energy source formed by the engine 40 and the electricalgenerating element 44 as well as one or more electrical energy sourcesthat are external to the electrical generator 10.

For example, FIG. 16 illustrates an embodiment where elements that aresimilar to elements in FIG. 3 are referenced using the same referencenumerals. FIG. 16 illustrates the electrical generator 10 as beingconnectable to utility lines 57 a external to the generator 10 thatprovide input AC power; one or more energy storage devices 57 b externalto the generator 10 such as one or more batteries that provide input DCpower; and one or more other electrical energy sources 57 c external tothe generator that can provide input AC or DC power. A power conversiondevice 58 a receives the AC power from the utility lines 57 a andconverts the incoming AC to DC. An optional power conversion device 58 bmay receive DC power from the energy storage device 57 b and convert theDC to AC. In addition, a power conversion device 58 c receives AC or DCpower from the energy source 57 c and convert the AC to DC or convertsDC to AC.

A switching system 59 is provided that can control the flow ofelectrical power between the power sources 40, 42, 57 a-c and the bus52. For example, the switching system 59 may be configured so that anyone of the power sources can provide electrical power to the bus 52. Theswitching system 59 may also be configured so that any two or more ofthe power sources can simultaneously provide electric power to the bus52. In another embodiment, the switching system 59 may be configured sothat electrical power is provided from the bus 52 to one of the powersources. For example, electrical energy generated from the engine 40 canbe directed to the utility lines 57 a to supply power to the electricalgrid or to the energy storage devices 57 b. The alternative powersources depicted in FIG. 16 be used with the systems illustrated inFIGS. 2 and 4 as well.

In some embodiments, the electrical generators 10 described herein canalso include a thermal control system 60 that can be configured toprovide a thermal control fluid for thermal control of a component thatis external to the electrical generator 10. For example, the thermalcontrol fluid can be provided to the component 16 and/or to thecomponent 18. In another example, the thermal control fluid can beprovided to a component that is not electrically connected to theelectrical generator 10. The thermal control system 60 may also beconfigured to supply the thermal control fluid to one or more componentsthat are internal to the electrical generator 10.

The thermal control fluid can be a liquid, gas, or a mixture of liquidand gas. The thermal control fluid can be a cooling fluid that cools theexternal/internal component, or a heating fluid that heats theexternal/internal component. In some embodiments, the system 60 may beconfigured to export a heated liquid for providing heat, either inaddition to the cooling liquid or without the cooling liquid. The heatedliquid can be used to, for example, heat one of the components 16, 18,and/or heat a component internal to the electrical generator 10, and/orheat any external component or structure such as a control cab, or usedfor any other purpose. When the system 60 exports a heated liquid, thesystem 60 may be referred to as a liquid heating system. The system 60may be referred to as a thermal control system regardless of whether itexports cooling liquid and/or heated liquid for heating.

For sake of convenience, the system 60 will hereinafter be described asa liquid cooling system that provides a cooled liquid as the thermalcontrol fluid. FIG. 5 illustrates one embodiment of the system 60configured as a liquid cooling system. The liquid cooling system 60 caninclude a liquid coolant tank 62 that is configured to contain a liquidcoolant and act as a supply of the liquid coolant, a coolant pump 64connected to the liquid coolant tank 62 for pumping the liquid coolantthrough the cooling system 60, and a heat exchanger (or chiller) 66 forcooling the liquid coolant. In addition, the system 60 includes acoolant supply manifold 68 with a plurality of outlet ports and an inletreceiving coolant from the coolant pump 64, and a coolant returnmanifold 70 with a plurality of inlet ports and an outlet connected tothe heat exchanger/chiller 66. The system 60 further includes at leastone externally accessible quick disconnect connector 72 for directingcoolant to, and receiving return heated coolant from, at least oneexternal heat generating component, such as the component 16 or adifferent component, via an umbilical that contains the coolant supplyand return lines 28 a, 28 b (FIG. 1 ). In this example, the coolingsystem 60, such as the tank 62, the pump 64 and the heatexchanger/chiller 66, are disposed within the housing 56.

As described in detail further below with respect to FIG. 14 , a thermalcontrol fluid supply bus and a thermal control fluid return bus can beprovided on the generator 10. The supply bus and the return bus can beconnected to in order to supply thermal control fluid to and returnthermal control fluid from one of the modules described below in FIG. 14, one of the electrical components 16, 18, or any external device thatis supplied with thermal control fluid from the generator 10.

In embodiments where the thermal control fluid is a liquid coolant, theliquid coolant can be any liquid coolant that is suitable for coolingthe heat producing component. For example, the liquid coolant can bewater mixed with an anti-freeze agent such as ethylene glycol orpropylene glycol, or an oil-based coolant. The tank 62 acts as areservoir for the liquid coolant to supply coolant and receive returningcoolant after performing its cooling function. The pump 64 pumps thecoolant through the system 60. The pump 64 can be an electric motordriven pump that is powered using the electrical power created by thegenerator 10 or mechanically driven via a suitable drive train by theoutput shaft 42 of the engine 40. The heat exchanger/chiller 66 receivesreturning coolant from the return manifold 70 and cools the liquidcoolant before it is returned into the tank 62. The heatexchanger/chiller 66 can have any configuration that is suitable forcooling the liquid coolant. For example, in the case of a heatexchanger, the heat exchanger can be configured as an air-to-liquid heatexchanger or configured as a liquid-to-liquid heat exchanger. Otherarrangements of the pump 64 and the heat exchanger/chiller 66 arepossible. For example, the heat exchanger/chiller 66 can be located onthe supply path of the coolant, for example between the pump 64 and thesupply manifold 68. In another embodiment, the pump 64 can be located onthe return path of the coolant, for example between the manifold 70 andthe heat exchanger/chiller 66.

The supply manifold 68 supplies the cooling liquid to variousdestinations in the cooling system 60 via its outlet ports. For example,a supply line 78 a can extend from one of the outlet ports in the supplymanifold 68 to the power converter 50 in order to direct the coolingliquid to the power converter 50 to cool the power converter 50. Inaddition, a supply line 78 b can extend from another one of the outletports in the supply manifold 68 to an external outlet in the quickdisconnect connector 72 (or to a coolant supply bus) to direct thecooling liquid externally of the electrical generator 10. In theillustrated example, the cooling liquid can be directed to both theexternal power converter 54 and an electric drive motor 74 that drivesthe component 16 (for example an impeller of a pit pump) for cooling thepower converter 54 and the electric drive motor 74. In the illustratedexample, the cooling liquid is directed serially through the electricdrive motor 74 and the power converter 54, with the cooling liquid firstcooling the electric drive motor 74 and then being directed into thepower converter 54 to cool the power converter 54 before the coolingliquid is directed back to the electrical generator 10. In anotherembodiment, the cooling liquid can be directed to the power converter 54first before being directed to the electric drive motor 74. In stillanother embodiment, the cooling liquid can be directed to the powerconverter 54 and the electric drive motor 74 in parallel where separatestreams of the cooling liquid are directed to the power converter 54 andthe electric drive motor 74. In some embodiments, if the power converter54 is not present or does not need cooling, the cooling liquid could besupplied just to the electric drive motor 74 to cool the electric drivemotor 74. Similarly, in some embodiments, of the electric drive motor 74does not require cooling or is not present, the cooling liquid can besupplied just to the power converter 54.

With continued reference to FIG. 5 , in some embodiments, other internalcomponents of the electrical generator 10, such as the electricalgenerating element 44 and the power converter 48, may also be configuredto be liquid cooled. In such a case, supply lines 78 c, 78 d extend fromrespective outlet ports in the supply manifold 68 to the electricalgenerating element 44 and the power converter 48. An optional bypassloop 80 may also be provided that extends between the supply manifold 68and the return manifold 70. The bypass loop 80 helps to increase thecooling capacity of the system 60.

The return manifold 70 receives the returning heated liquid coolant fromthe various cooling destinations in the cooling system 60. For example,a return line 82 a extends from the power converter 50 to one of theinlet ports in the return manifold 70, and a return line 82 b extendsfrom an external inlet in the quick disconnect connector 72 (or from acoolant return bus) to one of the inlet ports in the return manifold 70.Additional return lines 82 c, 82 d extend from the electrical generatingelement 44 and the power converter 48, respectively, to respective inletports in the return manifold 70.

Optionally, temperature sensors 84 and flow meters 86 can be provided inthe return lines 82 a-d. The temperature sensors 84 and the flow meters86 provide data that is useful for providing health monitoring and/orperformance optimization of the electrical generator 10 and itscomponents, as well as health monitoring and/or performance optimizationof the heat generating component(s) 74. Data from the temperaturesensors 84 and the flow meters 86 can be fed to suitable control logicto monitor these parameters. Variations in the individual temperaturesand flows of the cooling liquid can indicate problems with therespective elements including, but not limited to, elements 44, 48, 50,54, 74, etc., and suitable signals can be generated to warn an operatorof a problem or potential problem.

FIG. 6 is a schematic depiction of a variation of the thermal controlsystem 60 from FIG. 5 . In the system 60 in FIG. 6 , elements that arethe same as elements in FIG. 5 are referenced using the same referencenumbers. The system 60 in FIG. 6 is similar to the system 60 in FIG. 5 ,with the tank 62, the pump 64, the heat exchanger 66, the supplymanifold 68, and the return manifold 70 internal to the housing 56.

The system 60 in FIG. 6 differs from FIG. 5 in that a flow selector 90is provided in the system 60 that can be used to divert the flow of thecoolant from the return manifold 70 to an external heatexchanger/chiller 92. The heat exchanger/chiller 92 can be connected tothe generator via quick connect connectors 94 or any other suitable formof fluid connector. In this embodiment, the flow selector 90 can beactuated so as to permit flow of the cooling liquid directly from thereturn manifold 70 to the internal heat exchanger/chiller 66. The flowselector 90 can also be actuated so as to direct flow of the coolingliquid from the return manifold 70 to the external heatexchanger/chiller 92, before flowing back into the generator to theinternal heat exchanger/chiller 66. Although the heat exchanger/chiller92 is depicted as being a stand-alone component, the heatexchanger/chiller 92 can be incorporated into the component 16 and/orinto the component 18. In some embodiments, one or more additional quickconnect connectors 94 (shown in dashed lines) can be provided forconnection with additional external devices.

With continued reference to FIG. 6 , external components can also beconnected in series and/or parallel to the flow of the cooling liquidfor cooling the external components. For example, FIG. 6 illustrates 3external components 96 a, 96 b, 96 c fluidly connected to and receivingcooling liquid via the supply line 78 a. The components 96 a, 96 b arefluidly connected in series whereby the cooling liquid flows through andcools the component 96 a before flowing to and cooling the component 96,and then being returned to the return manifold 70. The component 96 c isfluidly connected in parallel with the component 96 b, where a portionof the cooling liquid is diverted from the component 96 a to thecomponent 96 c for cooling the component 96 c before being returned tothe return manifold 70. In other embodiments, the cooling liquid can bediverted to the components 96 b, 96 c before flowing into the component96 a.

FIG. 7 is a schematic depiction of another variation of the thermalcontrol system 60 from FIGS. 5 and 6 . In the system 60 in FIG. 7 ,elements that are the same as elements in FIGS. 5 and 6 are referencedusing the same reference numbers. The system 60 in FIG. 7 is similar tothe system 60 in FIGS. 5 and 6 , with the tank 62, the pump 64, the heatexchanger 66, the supply manifold 68, and the return manifold 70internal to the housing 56.

The system 60 in FIG. 7 differs from the system in FIG. 6 in that thecooling liquid from the supply line 78 a initially flows into a firstexternal component, such as the component 18, to cool the first externalcomponent, and the cooling liquid is then directed into and cools thesecond external component, such as the component 16, before beingreturned to the return manifold 70. In the embodiment in FIG. 7 , thesystem 60 is configured so that the first and second external componentsreceive the cooling liquid in series. In another embodiment, the firstand second external components can receive the cooling liquid in series,with the second external component receiving the cooling liquid firstfollowed by the first external component receiving the cooling liquidbefore returning to the return manifold 70.

In some embodiments, the electrical generator 10 can include the twooutputs 12, 14 without the thermal control system 60 of FIGS. 5-7 . Inother embodiments, the electrical generator 10 can include only one ofthe outputs 12, 14 together with the thermal control system 60 of anyone of FIGS. 5-7 .

Referring to FIG. 8 , an embodiment of a control system architecture 100of the electrical generator 10 is illustrated. Elements that are thesame as elements in FIGS. 1-7 are referenced using the same referencenumbers. A removable and replaceable user interface module 102 isinstalled on the electrical generator 10 for controlling operation ofthe electrical generator 10 based on the component 16 that is connectedto or to be connected to the modulated electrical output, or optionallybased on the component 18 that is connected to or to be connected to theexport electrical power output. Instead of being installed on theelectrical generator 10, the user interface module 102 can be usedremotely from the electrical generator 10 (as indicated in broken line)to control the electrical generator 10.

In some embodiments, the user interface module 102 can be replaced withone of a plurality of additional user interface modules 102 a...102 neach one of which is specifically configured to be installed on theelectrical generator 10 depending upon the external component 16 to bepowered by the generator 10. Each user interface module 102, 102 a,...102 n is specifically configured for use with its associated externalcomponent 16 to control the electrical generator 10 to ensure that thecorrect electrical power required by the component 16 is supplied at themodulated electrical output 12. Since each different component 16 thatmay be connected to the modulated electrical output 12 may require adifferent modulated electrical power, the modulated electrical power atthe modulated electrical output 12 can be different for each userinterface module 102, 102 a,... 102 n. The user interface modules 102,102 a,... 102 n can individually and removably plug into a modulemounting location 103 on the electrical generator 10. In otherembodiments, instead of adding a new interface module, the programmingof the interface module 102 can be changed or added to in order to add anew component 16 so that the interface module 102 can be used with eachnew component 16 by modifying the programming of the interface module102 based on each new component 16.

With continued reference to FIG. 8 , the control system architecture 100is also illustrated as including a Bluetooth module 104 that can connectto a smart device, such as a smart phone or tablet, via Bluetooth toreceive feedback from the electrical generator 10 and to permit controlof the electrical generator 10 by the smart device, a communicationmodem 106 to permit remote connection to a remote controller, such as apersonal computer or the like, to receive feedback from the electricalgenerator 10 and to permit control of the electrical generator 10 by theremote controller, a slave module 108 that receives sensor signals andoutputs all control signals for the electrical generator 10, and anisolation monitor 110 that forms an electrical safety system thatmonitors electrical isolation between the chassis of the electricalgenerator 10 and high voltage.

The electrical generator 10 described herein can be used at any locationwhere electrically powered components that require different types ofelectrical power are utilized. One specific application of theelectrical generator 10 will be described with respect to FIG. 9 . Inthis example application, the electrical generator 10 is used at a sitewhere horizontal directional drilling is occurring. In particular, thesite includes a horizontal directional drilling (HDD) rig 110 and a pitpump 112. The HDD rig 110 is configured to perform horizontaldirectional drilling which is well known to those of ordinary skill inthe art. The HDD rig 110 can be electrically powered with componentssuch as traverse carrier drive components and drill pipe rotationcomponents driven by electric motors. The HDD rig 110 can also includeother electrically powered components such as a chiller system that ispart of a cooling fluid circuit that circulates and cools a refrigerantliquid that is circulated through various ones of the electric motors onthe HDD rig 110 for cooling the electric motors. An example of anelectrically powered HDD rig 110 is disclosed in U.S. Pat. ApplicationPublication 2017/0342816, the entire contents of which are incorporatedherein by reference.

The pit pump 112 is disposed in a pit 114, submerged in drilling fluid,and is configured to pump the drilling fluid to a recycling system ofthe HDD rig 110 to be recycled for re-use by the HDD rig 110. The pitpump 112 is part of a drilling fluid recycling system that is used torecycle used drilling fluid for re-use during a borehole drillingoperation. Used drilling fluid from the drilling operation, mixedtogether with solids from the borehole, can collect in the pit 114,which can be an exit pit or an entry pit, with the used drilling fluidmixed with solids then being pumped by the pit pump 112 to the rest ofthe recycling system where the used drilling fluid is processed toremove the solids and to make the drilling fluid otherwise suitable forpumping back into the borehole. The construction and operation of adrilling fluid recycling system in a HDD system is well known in theart. The pit pump 112 includes an electric drive motor (such as themotor 74 shown in FIG. 5 ) that drives a pump impeller. A suitable pitpump is available from LaValley Industries of Bemidji, Minnesota.

With continued reference to FIG. 9 , the drive motor of the pit pump 112is electrically connected to the output 12 to receive the modulatedelectrical power for powering the drive motor. At the same time, one ormore electrical components on the HDD rig 100 (or other electricalcomponent(s) at the drilling site) can be electrically connected to theoutput 14 to receive the export electrical power. In addition, withreference to FIGS. 5 and 9 , the drive motor of the pit pump 112 may beconfigured to be liquid cooled, in which case the drive motor is fluidlyconnected to the quick disconnect connector 72 of the electricalgenerator 10 to receive cooling fluid or other thermal control fluidfrom the thermal control system 60 thereof for cooling the drive motor,with the cooling fluid then being recirculated back to the electricalgenerator 10 for removing heat from the cooling fluid.

With reference to FIGS. 5-7 , in one embodiment, the electricalgenerator 10 can adjust a temperature of the thermal control fluiddirected to the external component(s). For example, a fan of theinternal heat exchanger/chiller can be turned on/off and/or the thermalcontrol fluid can be directed to the external heat exchanger/chiller 92to adjust the temperature of the thermal control fluid. The temperatureof the thermal control fluid can be determined using suitabletemperature sensor(s), for example the temperature sensor 84 in thereturn line 82 b and/or a temperature sensor in the supply line 78 band/or a temperature sensor on the output from the tank 62. When theexternal component to be thermally controlled is an electric drivemotor, such as the electric drive motor of the pit pump 112, adjustingthe temperature of the thermal control fluid directed to the drive motoradjusts the performance capacity/efficiency of the electric drive motor,e.g. adjusts the power or revolutions per minute (RPMs) of the electricdrive motor because the electric drive motor is more efficient thecooler it is.

In one embodiment of the electrical generator 10 described herein, theRPM’s of the engine can be varied based on the load connected to theoutput 12 in order to maximize the operating fuel efficiency of theengine 40 based on the specific load. In addition, the export electricalpower at the output 14 allows the generator 10 to operate traditionalsynchronous electrical loads at all common voltages including 120 V, 240V, 480 V, etc. By providing both the modulated electrical power and theexport electrical power, either one can be used at full power (i.e. themodulated electrical power can output 100% of the electrical generator10 power capacity with the export electrical power outputting 0%; or theexport electrical power can output 100% of the electrical generator 10power capacity with the modulated electrical power outputting 0%). Inaddition, the power can be split between both the modulated electricalpower and the export electrical power simultaneously. If the electricalgenerator 10 has more than two electrical outputs, the power can besplit among the various electrical outputs. The power can be split inany ratio. However, the available generator power (i.e. 100% capacity)cannot be exceeded. In one embodiment, power can be prioritized by thecontrol system of the electrical generator 10 to the external component16, 18 that needs the most power. The prioritization can be manually setor automatically set based on communications from the component(s) 16,18. For example, when a component 16, 18 is connected to the generator10, the component 16, 18 can inform the generator 10 of its powerrequirements and thus of its priority.

In the embodiments described herein, either output type can be selectedas a priority. For example, if the modulated electrical power isselected as a priority, the export electrical power will be reduced inproportion to any increase in the modulated electrical power so that thetotal remains 100%. Likewise, if the export electrical power is selectedas a priority, the modulated electrical power will be automaticallyreduced in proportion to any increase in the export electrical power sothat the total remains 100%. For example, with the modulated electricalpower selected as a priority, as the modulated electrical powerincreases toward 100%, the export electrical power will be automaticallydecreased proportionally toward 0%.

In addition, in the embodiments described herein, a user can also bepermitted to select a power ratio limit that will, if needed,automatically limit the modulated electrical power and the exportelectrical power to the selected ratio. For example, if one selects aratio of 70%-30% of the modulated electrical power versus the exportelectrical power, the modulated electrical power would be limited to amaximum of 70% of the total generator capacity if the device(s) usingexport electrical power is using its allotted 30% limit of the totalgenerator capacity. In this example, if the device(s) using exportelectrical power is using only 10% (or some other value less than 30%)of the total generator capacity, the modulated electrical power canexceed the 70% limit by a corresponding amount. However, if thedevice(s) using the export electrical power then increases to 30%, themodulated electrical power would then be reduced to the 70% limit.

The electrical generator 10 also provides fuel savings by the uniquesystem architecture that provides the modulated electrical power whichallows the engine 40 to operate at lower RPM’s when the load is lowerreducing power consumption and un-necessary wear. Health monitoring canalso be provided on the components of the electrical generator 10 toprovide state of the art feedback of all critical operating parameterssuch as duty cycle, temperature, peak cycle, vibration, and the like.Each of the components including, but not limited to, the components 16,18, 40, 44, 48, 50, 50', 54, 54' 62, 64, 66, 68, 70, etc., can bemonitored using temperature sensors, and other sensors, which readingscan be fed directly to the user interface module 102, or to the slavemodule 108 and then the user interface module 102. The readings serve toprovide health monitoring of the various components of the electricalgenerator 10 and used with the generator 10.

With reference to FIG. 10 , in one embodiment two or more of theelectrical generators 10 can be connected in parallel to increasecapacity in electrically driving a load, for example driving thecomponent 16 and/or driving the component 18. Further description onparalleling two or more electrical generators is discussed below withrespect to FIGS. 14 and 15 .

FIGS. 11-13 illustrate another embodiment of the electrical generator10. In this embodiment, the electrical generator 10 uses a plurality ofmodules, including output modules that incorporate the differentelectrical outputs 12, 14. The internal components of the generator 10in FIGS. 11-13 can be similar to the generator 10 in FIGS. 1-7 ,including the engine 40 (or other AC input power source), the outputshaft 42, the electrical generating element 44, the first powerconverter 48, and the thermal control system 60. In some embodiments,one or more of the power converters may also be included in thegenerator of FIGS. 11-13 . However, in the embodiment of FIGS. 11-13 ,the power converters 50, 50', 50-1, 50-2, 54, 54' described herein arepreferably included within output modules that are removably installablein the electrical generator 10.

For example, with continued reference to FIGS. 11-13 , the generator 10can include a first power output module 120, a second power outputmodule 122, and optionally a third power output module 124. The firstpower output module 120 can be configured to output, via the electricaloutput 12 incorporated into the module 120, the desired form of ACelectrical power for powering the component 16. The module 120 includesthe power converter 54, 54' that converts the DC power from the DC busto the desired form of AC electrical power. Similarly, the second poweroutput module 122 can be configured to output, via the electrical output14 incorporated into the module 122, the desired form of AC electricalpower for powering the component 18. The module 122 includes the powerconverter 50, 50' that converts the DC power from the DC bus to thedesired form of AC electrical power. The optional third power outputmodule 124 can be configured to output a lower power from the electricaloutput 14-2, such as AC electrical power with a lower voltage than theoutput 14, for example as described above with respect to the output14-2 of FIG. 4 . The module 124 includes the power converter 50-2 thatconverts the DC power from the DC bus to the desired form of lower powerAC electrical power.

The power output modules 120, 122, 124 are each removably installed inthe generator 10. As a result, the power output of the generator 10 canbe modified by using any combination of the modules 120, 122, 124,and/or replacing one of the modules 120, 122, 124 with a similar modulethat is configured with a different power converter to change the ACelectrical power output therefrom. In some embodiments, a separatemodule, or one of the power output modules 120, 122, 124, can beconfigured to output DC power therefrom which DC power is modified fromthe form obtained from the DC bus. In some embodiments, instead ofhaving a module that modifies the DC power, the DC power from the DC busneed not be modified and unmodified DC power from the DC bus can beoutput directly from the DC bus including from a power output module.

Each power output module can be configured based on the device intendedto be connected to the power output module and/or based on the functionof the power output module. For example, if the pit pump 112 of FIG. 9is to be connected to the generator 10, the power output module to beconnected to by the pit pump is configured to output electrical powersuitable for the pit pump 112. Similarly, if a component on the HDD rig110 of FIG. 9 is to be connected to the generator 10, the power outputmodule to be connected to by the HDD rig component is configured tooutput electrical power suitable for the HDD rig component. Theelectrical generator 10 may also be used to charge an electric vehicle(EV) in which case a power output module, which may be referred to an EVcharging module, is configured to output electrical power suitable forcharging the EV. Many other examples of power output modules arepossible.

With continued reference to FIGS. 11 and 12 , the first power outputmodule 120 can also include a data port 126 for exporting data fromand/or inputting data into the module 120. In addition, the module 120can also include thermal control fluid inlet and outlet ports 128 a, 128b that can be used to direct thermal control fluid from the internalthermal control system 60 of the generator 10 to the component 16receiving power from the module 120. The thermal control fluid from theinternal thermal control system 60 can be input into the module 120 viasuitable fluid connectors (not shown) on the rear of the module 120 thatare fluidly connected to fluid connectors 130 (see FIG. 14 ) within thegenerator 10. The fluid connectors 130 can be configured for manualconnection, or they can be blind mate, quick connect fluid couplers. Thefluid connectors 130 can be part of a thermal control fluid bus assemblyformed on each one of the generators 10, with one of the fluidconnectors 130 of each pair of fluid connectors 130 connected to athermal control fluid supply bus that is fluidly connected to the supplymanifold 68 (see FIG. 5 ) and the other one of the fluid connectors 130of each pair being connected to a thermal control fluid return bus thatis fluidly connected to the return manifold 70 (see FIG. 5 ). Thethermal control fluid directed into the module 120 can also be used tothermally control the internal power converter and other heat generatingcomponents of the module 120. If desired, thermal control fluid inletand outlet ports similar to the ports 128 a, 128 b can also be providedon the modules 122, 124.

Returning to FIGS. 11-13 , the generator 10 can also include aparalleling module 132 and at least one module expansion slot 134covered by a removable cover 136. The paralleling module 132 isconfigured for interconnecting the generator 10 in parallel with one ormore additional ones of the generators 10 as illustrated in FIG. 14 .For example, in the illustrated embodiment, the paralleling module 132is provided with upper, input and lower, output rows 138 a, 138 b ofpositive, negative and ground terminals for connecting the generators 10in parallel using suitable paralleling cables 140 depicted in FIG. 14 .Returning to FIGS. 11-13 , the module expansion slot 134 is configuredto permit the addition of one or more additional modules 142 (depictedin dashed lines in FIG. 13 ) to the generator 10 when the cover 136 isremoved. The additional module 142 can be an additional one of the poweroutput modules 120, 122, 124. In another embodiment, the additionalmodule 142 can be a thermal control module used for thermallycontrolling the thermal control fluid, for example the thermal controlmodule can include the external heat exchanger/chiller 92 describedabove with respect to FIGS. 6 and 7 . In still another embodiment, theadditional module 142 can be used as a thermal control module that actsas a cooling and/or heating module. When configured as a cooling module,the module can act as a source for directing additional flows of theliquid coolant from the internal liquid cooling system 60 of thegenerator 10 to external devices needing cooling. When configured as aheating module, the module can direct heated coolant externally forheating use, for example to heat a building, a control cab of an HDDrig, or other heating need. The thermal control module can also includea plurality of liquid inlet and outlet ports on the front side thereofpermitting connection of fluid lines for directing the cooled liquidcoolant to one or more external devices needing cooling or directing theheated coolant to one or more external devices needing heating.

Referring to FIGS. 13 and 14 , electrical power for the modules 120,122, 124, 132 of the generator 10 can be provided via DC bus bars 144that form the DC output bus 52 of the generator 10. Each one of themodules is configured to electrically connect to the DC bus bars 144.The modules can electrically connect to the DC bus bars 144 in anysuitable manner. For example, as best seen in FIG. 13 , the rear side ofthe each module can include electrical connectors 146 that connect tothe DC bus bars 144. The electrical connectors 146 can be blind mateelectrical connectors that automatically connect to the DC bus bars 144when each module is slid into position in its slot in the generator 10,and that automatically disconnect from the DC bus bars 144 when eachmodule is removed from the generator 10. Similarly, the modules 120,122, 124, 132 can each include blind mate, quick connect fluid couplersthat automatically blind mate connect with the blind mate, quick connectfluid couplers 130 when each module is slid into position in its slot inthe generator 10, and that automatically disconnect when each module isremoved from the generator 10.

FIG. 14 illustrates a plurality of the generators 10 connected to oneanother in parallel. In the illustrated example, the generator 10 on theright is configured to output electrical power via the output modules120, 122, 124. The generator 10 on the right is able to supply 100% ofthe electrical power that is available from all of the generators 10.However, modules can be added to any of the generators 10. For example,the second generator 10 is illustrated as including the output module120 (in dashed lines) and the output module 122 (in dashed lines). Thegenerators 10 have a common bus connection. The modules can be locatedin any generator 10 and connect to the common bus while sharing thesingle common bus power source.

Any generator 10 can be contributing as little or as much electricalpower to the bus as needed. Load management control can be used to shedgenerators 10 or bring generators 10 on as needed without changingconnections between the generators 10 since there is a single commonbus. In particular, the RPMs of the engines 40 of the paralleledgenerators 10 can be automatically controlled. For example, in the caseof multiple paralleled generators 10, all of the generators 10 may becontrolled so as to adjust their RPMs up or down as needed to match thesystem load. If the system load that is required becomes less than theparalleled generators 10 are producing, then one or more of thegenerators can be shed (i.e. shut down or its power output notcontributing to the total power output of the paralleled generators) asneeded. If the system load thereafter increases, then one or more of thegenerators can be brought back on as needed to contribute to the totalpower output as.

FIG. 15 illustrates the common DC bus connection of the paralleledelectrical generators 10 of FIG. 14 . Each generator 10 contributes tothe common DC bus 150 of the system, and each output module 120, 122,124 draws electrical power from the common DC bus 150 for powering itsassociated load (e.g. components 16, 18). In some embodiments, the bus150 can be an AC bus.

So the configurations in FIGS. 11-15 permit electrically connecting aplurality of the generators 10 in parallel via a DC bus. In addition,the performance of the generator 10 can be modified by replacing one ofthe modules, for example one of the power output modules 120, 122, 124,with another module that is configured to have different performance,for example outputting a different amount or type of AC power or DCpower in the case of the power output modules 120, 122, 124.

FIG. 17 illustrates another example of a common bus connection. Elementsin FIG. 17 that are the same as elements in FIG. 15 are referenced usingthe same reference numerals. In FIG. 17 , a plurality of the electricalgenerators 10 are depicted as being connected in parallel. In addition,one or more energy storage devices, which can be similar to the energystorage device 57 b of FIG. 16 , may also be connected to the bus 150.The energy storage device(s) 57 b can be part of or separate from theelectrical generator(s) 10 and can be used to store electrical energygenerated by the electrical generator(s) 10. The energy storagedevice(s) 57 b can be any energy storage device that can storeelectrical energy. For example, the energy storage device(s) 57 b can beone or more batteries, capacitors, and the like. The energy storagedevice(s) 57 b may also be used to provide electrical power for use bythe output modules 120, 122, 124, or the energy storage device(s) 57 bcan be used to provide electrical power for any device external to theelectrical generator(s) 10. When the energy storage device(s) 57 b isprovided, a power output module 120, 122, 124 that is configured for usein outputting electrical energy from the energy storage device(s) 57 band/or controlling charging of the energy storage device(s) 57 b can beprovided.

FIG. 18 illustrates another example of a common bus connection. Elementsin FIG. 18 that are the same as elements in FIGS. 15 and 17 arereferenced using the same reference numerals. FIG. 18 depicts one ormore of the electrical generators 10 connected to the bus 150 along withthe utility lines 57 a, one or more of the energy storage devices 57 b,and the other energy source 57 c. Referring to FIGS. 16 and 18 , thegenerator 10 acts as an energy handling system, where the electrical bus150 is electrically connectable to a first source of electrical powerwithin the housing 56 or enclosure, and is also electrically connectableto a second source of electrical power external to the enclosure, suchas the utility lines 57 a, the energy storage 57 b and/or the otherenergy source 57 c. In addition, a plurality of electrical power outputscan be provided, for example via the output modules 120, 122, 124, wherethe power outputs can be connected to in order to direct electricalpower to the external loads 16, 18 that are external to thehousing/enclosure. In some embodiments, the bus 150 can receiveelectrical power from the second, external source of electrical powerand the bus 15 can also be used to direct electrical power to thesecond, external source of electrical power, for example to directexcess electrical power to the electrical grid via the utility lines 57a and/or to charge the energy storage device(s) 57 b.

FIG. 19 illustrates another embodiment where the bus 150, and a supplymanifold 200 and a return manifold 202 for the thermal control fluid areintegrated together in a common assembly 204 (illustrated schematicallyby the dashed line box). In FIG. 19 , elements that are identical orsimilar to elements previously described above are referenced using thesame reference numerals. The common assembly 204 forms a commonstructure where both electrical energy transfer and thermal energytransfers take place. The common assembly 204 can be integrated into theelectrical generator structures described herein. In another embodiment,the common assembly 204 can be a structure that is physically separatefrom the electrical generator structures described herein, but which canbe interfaced with the electrical generator structures described herein.

Different sources of electrical power can electrically connect to thebus 150 of the common assembly 204 to direct electrical power into thebus 150 and/or to receive electrical power via the bus 150. The sourcesof electrical power can include, but are not limited to, the engine 40and the generator 44, the utility lines 57 a, the energy storage devices57 b, a solar panel array 57 d, a fuel cell 57 e, or a microturbine 57f. Power conversion devices 58 d, 58 e, 58 f are connected to the array57 d, the fuel cell 57 e and the microturbine 57 f, respectively, toconvert and/or condition the electrical energy in a manner making itsuitable for input to the bus 150. FIG. 19 depicts the utility lines 57a feeding electrical power to and/or receiving electrical power from thepower conversion device 48 via a transfer switch 206. However, theutility lines 57 a can have their own power conversion device, like thepower conversion device 58 a in FIG. 16 .

With continued reference to FIG. 19 , different power consumingcomponents can be electrically connected to the assembly 204 to receiveelectrical power from the bus 150 and/or to receive thermal controlfluid from the supply manifold 200. The power consuming components canbe any components that can be powered by electrical power received fromthe assembly 204 and/or that can receive thermal control fluid from theassembly 204 for use in thermal control of the power consumingcomponent. For example, the components can be the components 16, 18, acomponent 208 that can be directly powered from DC (or AC) power of thebus 150 (i.e. without requiring a power converter), a DC poweredcomponent 210 that has a DC/DC power converter 212, an AC higher poweredcomponent 214 that has a DC/AC power converter 216 providing higher ACpower, and an AC lower powered component 218 that has a DC/AC powerconverter 220 providing lower AC power (i.e. lower than the DC/AC powerconverter 216).

One or more of the power consuming components in FIG. 19 can also befluidly connected to the supply manifold 200 and the return manifold 202for directing thermal control fluid to and from the power consumingcomponent(s) for performing thermal control of components on orassociated with the power consuming components. For example, for eachpower consuming component, a supply line 222 fluidly connects the powerconsuming component and the supply manifold 200 to direct incomingthermal control fluid to the power consuming device, and a return line224 fluidly connects the power consuming component and the returnmanifold 202 to direct returning thermal control fluid from the powerconsuming device to the heat exchanger/chiller 66.

FIG. 19 also depicts a control system 230 that can be used to controlsome or all of the system depicted in FIG. 19 . For example, the controlsystem 230 can be in communication with the pump 64 and each of thepower sources 40, 57 a, 57 b, 57 d, 57 e, 57 f. The control system 230can also be in communication with the power conversion devices 48, 58 b,58 d, 58 e, 58 f, flow control valves 232 in the supply line 222 and thereturn line 224, and communication interfaces 234 associated with thepower consuming components 16, 18, 208, 210, 214, 218. The controlsystem 230 can receive data inputs from the various elements to allowmonitoring of performance. The control system 230 can also controloperation of the various elements. For example, the control system 230can determine which electrical power source(s) 40/44, 57 a, 57 b, 57 d,57 e, 57 f supplies electrical power to the bus 150 and/or directelectrical power from one power source, such as the power source 40/44,to the utility lines 57 a and/or to the energy storage devices 57 b. Thecontrol system 230 can also control the flow of thermal control fluid toand from the power consuming devices by controlling the flow controlvalves 232.

FIG. 20 illustrates a non-limiting example of how the bus 150, and thesupply manifold 200 and the return manifold 202, can be integratedtogether in the common assembly 204. In this example, metallic pipesforming the supply manifold 200 and the return manifold 202 form the bus150, with the pipe of the supply manifold 200 forming the positiveportion of the bus 150 and the return manifold 202 forming the negativeportion of the bus 150. The pipes can be formed of any material suitablefor conducting electricity sufficient to act as a DC (or AC) bus. Forexample, the pipes can be made of metal including, but not limited to,copper, brass or aluminum. However, other techniques for integrating thebus 150 and the manifolds 200, 202 into the common assembly 204 arepossible.

FIG. 20 also depicts an example of how the power consuming components16, 18, 208, 210, 214, 218 can be fluidly and electrically connected tothe assembly 204. For example, the hoses forming the supply line 222 andthe return line 224 can be electrically conductive, and the controlvalves 232 can be zero leak fluid connectors that are also electricallyconductive. Electrically conductive hoses and fluid connectors are knownin the art and available from Parker Hannifin Corporation.

Additional aspects described herein can include the following:

An electrical generator can include: an engine having a mechanicaloutput; an electrical generating element connected to the mechanicaloutput, the electrical generating element is configured to generate analternating current; a power converter electrically connected to theelectrical generating element and receiving the alternating currenttherefrom, the power converter is configured to convert the alternatingcurrent to a direct current; a direct current bus electrically connectedto the power converter and receiving the direct current therefrom; afirst electrical power output electrically connected to the directcurrent bus and that outputs a first type of electrical power; a secondelectrical power output electrically connected to the direct current busand that outputs a second type of electrical power, where the secondtype of electrical power differs from the first type of electricalpower; and a control system connected to the engine and that isconfigured to monitor a first load that electrically connects to thefirst electrical power output and/or monitor a second load thatelectrically connects to the second electrical power output, and thecontrol system automatically adjusts output revolutions per minute ofthe engine based on the monitored first load and/or the second load.

The electrical generator can further include a plurality of power outputmodules, each one of the power output modules is removably installableon the electrical generator, a first one of the power output modulesincludes the first electrical power output and second one of the poweroutput modules includes the second electrical power output. In anembodiment, each one of the power output modules can includes a busconnector at one thereof that electrically connects to the directcurrent bus.

In an embodiment, the direct current bus of the electrical generator iselectrically connectable to utility power.

The electrical generator can further include a thermal control systemthat provides a thermal control fluid, at least one fluid outlet in theelectrical generator from which the thermal control fluid can exit theelectrical generator to an external device, and at least one fluid inletthrough which the thermal control fluid can be returned into theelectrical generator and to the thermal control system. In anembodiment, the thermal control system can include a heat exchangerthrough which the thermal control fluid is directed to adjust thetemperature of the thermal control fluid. In another embodiment, the atleast one fluid inlet and the at least one fluid outlet are disposed ona power output module that is removably installed on the electricalgenerator, and the power output module includes the first electricalpower output or the second electrical power output.

The electrical generator can further include a paralleling moduleremovably installed on the electrical generator and electricallyconnected to the direct current bus, and the paralleling module includesa plurality of positive terminals and a plurality of negative terminals.

In another embodiment, an electrical generator can include: an enginehaving a mechanical output; an electrical generating element connectedto the mechanical output, the electrical generating element isconfigured to generate an alternating current; a power converterelectrically connected to the electrical generating element andreceiving the alternating current therefrom, the power converter isconfigured to convert the alternating current to a direct current; adirect current bus electrically connected to the power converter andreceiving the direct current therefrom; a plurality of modules each ofwhich is removably installable on the electrical generator, each moduleincludes a bus connector that electrically connects to the directcurrent bus when the module is installed on the electrical generator, afirst one of the modules is configured to output a first type ofelectrical power at a first electrical power output when installed onthe electrical generator to provide electrical power to a first load,and a second one of the modules is configured to output a second type ofelectrical power at a second electrical power output when installed onthe electrical generator to provide electrical power to a second load,where the first type of electrical power differs from the second type ofelectrical power.

In the electrical generator of the preceding paragraph, the first one ofthe modules includes a first power converter and the first type ofelectrical power comprises a first alternating current, the second oneof the modules includes a second power converter and the second type ofelectrical power comprises a second alternating current that differsfrom the first alternating current.

In another embodiment, in the electrical generator, the direct currentbus can be electrically connectable to utility power.

The electrical generator can further include a thermal control systemthat provides a thermal control fluid, at least one fluid outlet in theelectrical generator from which the thermal control fluid can exit theelectrical generator to an external device, and at least one fluid inletthrough which the thermal control fluid can be returned into theelectrical generator and to the thermal control system. In anembodiment, the thermal control system can include a heat exchangerthrough which the thermal control fluid is directed to adjust thetemperature of the thermal control fluid. In another embodiment, the atleast one fluid inlet and the at least one fluid outlet are disposed onthe first one of the modules or on the second one of the modules.

In another embodiment, in the electrical generator one of the modulescan be a paralleling module that includes a plurality of positiveterminals and a plurality of negative terminals.

The examples disclosed in this application are to be considered in allrespects as illustrative and not limitative. The scope of the inventionis indicated by the appended claims rather than by the foregoingdescription; and all changes which come within the meaning and range ofequivalency of the claims are intended to be embraced therein.

1-18. (canceled)
 19. An electrical generator comprising: an electricalbus within the electrical generator, the electrical bus is electricallyconnectable to a source of electrical power within the electricalgenerator; a plurality of modules each one of which is configured to beremovably installable on the electrical generator, each module includesa bus connector that electrically connects to the electrical bus whenthe module is installed on the electrical generator, and each moduleincludes an electrical output.
 20. The electrical generator of claim 19,wherein the generator includes a thermal control fluid bus.
 21. Theelectrical generator of claim 20, wherein at least one of the modulesfurther includes a thermal control fluid inlet port, a thermal controlfluid outlet port, and fluid connectors that fluidly connect to thethermal control fluid bus when the at least one module is installed onthe electrical generator.
 22. The electrical generator of claim 20,further comprising a thermal control module that is configured to beremovably installable on the electrical generator, the thermal controlmodule includes at least one thermal control fluid inlet port, at leastone thermal control fluid outlet port, and fluid connectors that fluidlyconnect to the thermal control fluid bus when the thermal control moduleis installed on the electrical generator.
 23. The electrical generatorof claim 19, wherein for each module, the electrical output outputs ACpower or DC power.
 24. The electrical generator of claim 19, wherein theelectrical bus comprises a DC bus or an AC bus.
 25. The electricalgenerator of claim 19, wherein at least one of the modules includes apower converter that converts DC power to AC power or that converts ACpower to DC power.
 26. An electrical generator comprising: an electricalbus within the electrical generator, the electrical bus is electricallyconnectable to a source of electrical power within the electricalgenerator; a plurality of modules each one of which is configured to beremovably installable on the electrical generator; at least one of themodules is a power output module that includes a bus connector thatelectrically connects to the electrical bus when the power output moduleis installed on the electrical generator, and the power output moduleincludes an electrical output; and at least one of the modules is athermal control module that includes at least one thermal control fluidinlet port, at least one thermal control fluid outlet port, and fluidconnectors that fluidly connect to a thermal control fluid bus of theelectrical generator when the thermal control module is installed on theelectrical generator.
 27. The electrical generator of claim 26, whereinpower output module further includes a thermal control fluid inlet port,a thermal control fluid outlet port, and fluid connectors that fluidlyconnect to the thermal control fluid bus when the power output module isinstalled on the electrical generator.
 28. The electrical generator ofclaim 26, comprising at least two of the power output modules.
 29. Theelectrical generator of claim 26, wherein the electrical output outputsAC power or DC power.
 30. The electrical generator of claim 26, whereinthe electrical bus comprises a DC bus or an AC bus.
 31. The electricalgenerator of claim 26, wherein power output module includes a powerconverter that converts DC power to AC power or that converts AC powerto DC power.